System for calculating floor plan information and automatically notching, cutting and transferring information onto framing components

ABSTRACT

An integrated system for modeling framed structures, quantifying framing information, and for automatically cutting and notching framing components (or alternatively for transferring a marking layout onto framing components for subsequent controlled cutting, notching, and placement). The system defines parametric models for a plurality of discrete wall panel components and wall panels incorporating the discrete wall panel component models. The system then defines an intersecting spatial relationship while tracking user progress to ensure completion, and compiles an overall parametric model. Once the model is completed, the system compiles design data and produces command signals which are fed to an automatic notching station for coordinating and controlling operation thereof. The notching station then automatically cuts and notches the framing components. Alternatively, the design data is used to produce command signals for a printer which transfers a marking layout onto framing components for subsequent controlled cutting, notching, and placement.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application derives priority from U.S. Provisional PatentApplication No. 60/073,101 filed Jan. 30, 1998, is acontinuation-in-part of U.S. application Ser. No. 07/587,960 filed Jan.17, 1996, and corresponds to International Application No.PCT/US98/03985 filed Feb. 3, 1998.

TECHNICAL FIELD

The present invention relates to computer automation of the buildingconstruction process and, more particularly, to an integrated system formodeling framed structures and for quantifying framing information, andincluding a method and device to automatically cut and notch framingcomponents, and/or to directly transfer a marking layout onto framingcomponents for subsequent controlled cutting, notching, and placement.

BACKGROUND ART

Light framing (commonly referred to as “stick framing”) is a commonmethod for the construction of buildings having up to four stories.Stick framing is typically performed on-site, hand-assembly of thecomponents being performed by experienced carpenters using raw materialsof random dimensions. The placement of the sticks in the building isdetermined by blueprints, shop drawings or other construction documents.Unfortunately, these hard copy construction documents lead to severaldrawbacks. First, the frequency of changes makes them cumbersome.Second, mistakes may easily be made by the layout man when reading andtransferring the information from the shop drawing to the plates. Third,mistakes may easily be made by either misreading the tape or mis-cuttingthe line as the plate is cut to length. Fourth, mistakes may be made atthe assembly point by misunderstanding the layout code or missing themark when nailing. Finally, when using wood studs, moisture causes thewood studs and components to twist within the wall after being nailed.This twisting cause nail pops in sheet rock and visible imperfections inwall finish, and results in substantial replacement costs. Thus, thereclearly remains a need for an arrangement which permits the controlledplacement, notching and cutting of components, such as studs, wallplates, shelving, lattices and furniture while minimizing potentialmistakes and inaccuracies, and which minimizes warping and twisting ofthe studs and other components after construction. The notched jointfixes the axial movement of the members in the system and improvesengineering design values.

There have been no known efforts to develop integrated automatic systemsfor the controlled modeling of framed structures, calculation of cuttingand notching layout therefrom, and actual automatic cutting and/ornotching of components and/or marking of components with a markinglayout for subsequent cutting, notching or assembly.

At the front end, a few prior attempts have been made to developapplication-specific computer modeling systems for generating 3D modelsof framed structures for construction purposes.

One exemplary program published by APDesign® is an architectural add-onfor AutoCAD®. The APDesign program is parametric-building program thatgenerates 3D models from 2D plans, working drawings, framing andquantifying information and site contours. The APDesign is arranged insix modules and a predefined database containing all building elementdescriptions, graphic data detail, prices and alternative codes, isshared by all the modules.

A Utility Module is the base module and provides the generic functionscommon to all the modules. The Utility Module assists in general designand the drafting process for 2D drawings, and makes provisions for 3Ddrafting.

An Architect Module functions to assist the architect in producing the3D models rendered by the Utility Module.

A Quantity Module focuses on assembly, scheduling and pricing. Itmeasures and collates the quantity of all building database elementscontained in a 3D model created by the Utility and Architecture Modulesor the Framing Modules.

A Framing Module automatically creates or inserts either timber or steelstud framing into walls, produces floor frame detail based on post,bearer and joist space, and provides a range of roof truss profiles.Once the frame data is created by its Wall Framing Stud function, aseries of optional functions like breaks, corners, bracing, etc, can beinvoked to complete the frame detailing.

A Survey Module produces detailed site information that may be combinedwith the 3D models produced by the Utility and Architect modules or theuser to create a standalone site survey drawing. Site survey informationsuch as property boundaries, spots levels and section data can behelpful in adding new items such as pipelines, pits and gullies in full3D form.

A Terrain Module allows point data to be entered into an AutoCAD,drawing directly or either through it or the Survey Module, and be usedto create a proportionally accurate graphic data set of any landsurface.

While APDesign can improve the efficiency of architects, it suffers froma lack of detail, flexibility, and ease of use. Moreover, APDesign ispurely for modeling. It has no practical ability to facilitate cuttingand notching of framing components, nor is there an ability to directlytransfer framing information onto framing components for subsequentcontrolled cutting, notching, and placement of intersecting components.

It would be greatly advantageous to provide an integrated process anddevice that begins with application specific modeling in the framingcontext, and which analyzes the model to quantify the cutting andnotching information for accurately controlling the notching, cuttingand/or marking of components such as studs, wall plates, openings, teesand corners, plus the floor and/or roof system layout, and associatedcomponents that may be located by reference to the layout such asplumbing, pipes, air conditioning, etc. Such an arrangement wouldeliminate the burden of working with blueprints, the errors associatedtherewith, and would minimize the twisting that the studs and thecomponents may undergo after being placed in the wall panel. Anintegrated system would also accelerate production levels byautomatically laying out, notching and cutting to length each componentwith minimal set-up time, even when the layout, notch locations and walllength vary infinitely and batch runs are not always practical.

Disclosure of Invention

The invention comprises an integrated system for modeling framedstructures and for quantifying framing information, and including amethod and device to automatically cut and notch framing components,and/or to directly transfer a marking layout onto framing components forsubsequent controlled cutting, notching, and placement.

The process for modeling framed structures includes the steps ofdefining parametric models for a plurality of discrete wall panelcomponents, defining parametric models for a plurality of wall panels,said wall panel models incorporating said discrete wall panel componentmodels, defining an intersecting spatial relationship between theplurality of wall panels, tracking user progress to ensure completion,and compiling an overall parametric model of the plurality of wallpanels, plurality of discrete components, and intersecting spatialrelationship.

Once the model is completed, it is compiled to quantify design data, andthe process may be extended to produce command signals which are fed toan apparatus to automatically move and notch the components inaccordance with the design.

The above-described process can be embodied as a software program on aconventional computer, and the computer becomes an essential element ofthe apparatus. The apparatus further comprises a supporting frame, anautomatic notching station carried by the supporting frame, the notchingstation including a notcher for notching said components, and a notchingcarriage for moving the notcher into cutting contact with thecomponents. The apparatus also includes a component moving carriagesupported by and positionable relative to the supporting frame foradvancing components into a notching position relative to the notchingstation. The computer is connected to the automatic notching station andcomponent moving carriage for coordinating and controlling operationthereof The computer sequentially advances the components into notchingposition relative to the notching station, moves the notcher intocutting contact with the components, and automatically notches thecomponents in accordance with predetermined design considerations.

Rather than directly cutting and/or notching the components, both theprocess and apparatus may be modified to directly transfer a markinglayout onto framing components for guiding cutting, notching andassembly thereof

BRIEF DESCRIPTION OF DRAWINGS

Some advantages of the disclosed invention will become apparent from areading of the following description when read in conjunction with theaccompanying drawings in which:

FIG. 1 is the Primary Editing window.

FIG. 2 is the File Retrieval window which opens an existing floorplan.

FIG. 3 shows a visual display 1 for the checklist of seven majorsubstantive tasks 2-8 which the user must complete in order to generatea proper floor plan.

FIGS. 4a through 4 f are a detailed flow-chart of the user stepsnecessary for completion.

FIG. 5 is the Material Code Screen.

FIG. 6 is the Configuration Window.

FIG. 7 is the Component Editor Window.

FIG. 8 is the Add Opening Box

FIG. 9 is the Value (entry) Box

FIG. 10 is the Consumed Space Criteria Setup by which wall intersectioncriteria are set.

FIG. 11 illustrates an exemplary user interface for importingpre-defined wall intersection criteria or any other framing componentsor parameters from an existing library.

FIG. 12 shows the beam configuration window by which beams are added tothe floor plan.

FIG. 13 shows the Wall Panel Side View Box.

FIG. 14 shows the Panel Editing Window.

FIG. 15 shows the “Build vs. Edit Discrepencies” window.

FIG. 16 is three-dimensional graphical illustration of a completed floorplan.

FIG. 17 is the Commit Panels Screen.

FIG. 18 is an opening cut list which lists all opening and opening typesin the floor plan and list of components by component type withspecifications necessary to build the openings.

FIG. 19 is an opening assembly list which lists all opening and openingtypes in the floor plan and a list of all components organized byopening.

FIG. 20 is a sheathing cut list which lists all sheathing sections to becut for all wall panels.

FIG. 21 is a lumber take-off list which totals the materials costs forall components.

FIG. 22 is a lumber pricing chart which lists the lumber SKU numbersused in calculating the materials costs in the report of FIG. 22.

FIG. 23 is a total pricing report which includes the saw costs andfabrication costs for all components.

FIG. 24 is the Plate Cutting Preview Screen.

FIG. 25 is a perspective view of the cutting and notching assembly ofthe present invention.

FIG. 26 is a perspective view of the cutting and notching assembly ofthe present invention illustrating partially finished top and base wallplates clamped within the cutting and notching assembly.

FIG. 27 is a diagrammatic side view of the cutting and notching assemblyof the present invention illustrating the initial position of theclamped wall plates to be notched and cut.

FIG. 28 is a diagrammatic side view of the cutting and notching assemblyof FIG. 27 illustrating the advancement of the traveling means (meansfor advancing the clamped wall plates) as it moves the wall plates intothe notcher.

FIG. 29 is a side view of the dado-cut saws being moved downwardly tonotch the wall plates.

FIG. 30 is a side view showing the dado-cut saws notching the wallplates.

FIG. 31 is a side view showing the dado-cut saws moving downwardly andoutwardly following notching of the wall plates.

FIG. 32 is a top view showing the wall plates in the present inventionprior to contact with the wedging means and the dado-cut saws.

FIG. 33 is a top view showing the wedging means against the wall platesand the dado-cut saws notching the wall plates.

FIG. 34 is a side view of FIG. 32 showing the wedging means and the wallplates.

FIG. 35 is a side view of FIG. 33 showing the wedging means engaging thewall plates.

FIGS. 36 and 37 are side views, enlarged for the sake of clarity, of thecut-off saw (cut-off means) of FIGS. 25-28, which is used for thecontrolled cutting of the notched wall plates.

FIG. 38 is an exploded perspective view of the traveling carriage 15,the wedging means 42, and the cut-off saw 25.

FIG. 39 illustrates another embodiment of the notching station 20 withdouble-sided notchers.

FIG. 40 illustrates an exemplary marking device 40 incorporated in thecontext if the automated cutting/notching/marking machine of the presentinvention.

FIG. 41 shows a floor plan which is exemplary of the number andplacement of the notched studs which form the wall panels on one storyof a typical building.

FIG. 42 is an assembly diagram of a wall frame manufactured inaccordance with the following invention.

BEST MODE(S) FOR CARRYING OUT THE INVENTION

With reference to the drawings wherein like reference charactersrepresent like components throughout the various views, there isdepicted a framing system comprising a parametric-building computerprogram that allows a user to quickly and conveniently generate andanalyze 3D models of framed structures. In addition, a marking layout isprovided for quantifying the framing information, as well as a processto automatically cut and notch framing components, and/or to directlytransfer framing information onto framing components for subsequentcontrolled cutting, notching, and placement of intersecting components.

The framing system of the present invention includes a software processwhich may be implemented on an existing computer workstation. Theworkstation can, for example, be a conventional personal computer andthe CPU/Internal components can be those which are commonly integratedtherein, e.g., a microprocessor with peripheral chipset mounted on anappropriate motherboard. More or less powerful computer systems can beused, but it is suggested that minimum system performance is realizedwith a 66 Mhz CPU processor with 16 Mb of RAM. The system may be easilyported to run on a MacIntosh operating system and minimum systemrequirements are comparable to the above-described PC-basedrequirements. The user interface includes a conventional monitorattached via a serial port to the CPU/Internal Components. It issuggested that best video results are gained with an SVGA 17″ monitorwith 1024×767 pixel resolution. The user input is through a conventionalkeyboard and a pointing device such as a mouse. Approximately 20 Mb ofdisk storage is required, and this may be provided in the form of acommercially available disk drive attached via known IDE or SCSIinterface to the CPU. The architecture must also include certainresident firmware including an operating system such as Windows 95® byMicrosoft, appropriate drivers for all internal hardware componentsincluding the above-described devices. The foregoing description of thearchitecture will be understood by one skilled in the art as merely anexample of one system which could be used to implement the variousembodiments of the computer program of the present invention describedin detail below and, and that various other configurations and devicescould also be used.

Once installed and initiated, the computer program of the presentinvention guides a user quickly through a series of steps in which allnecessary components of a framed structure are defined, assembled,compiled and analyzed, including wall panels, tees and intersections,openings, etc. During each step in the process the user is presentedwith simple graphical interfaces that provide all of the software toolsnecessary to define and assemble the components of the framed structure.A primary advantage of the invention lies in its intuitive organizationand flow, e.g., all necessary components, sub-components,sub-sub-components, etc. are defined by the user and stored in a library(the library being arranged in layers corresponding to the level ofdetail of the component). Then, the pre-defined components may be addedto the floor plan as desired. Finally, the floor plan may be compiledand assimilated into a complete three-dimensional model.

The program initializes to the Primary Editing window of FIG. 1 which isa graphical user interface that provides a windows-based text menu atthe top and a corresponding series of graphical icons that serve asmeans for navigating the program. By clicking on the text menu at FILE,the user may Open an existing floor plan, Save a floor plan (ifcurrently open), Create a new floor plan, Delete a floor plan, Export afloor plan (if currently open) to a variety of other file formats foruse in other programs, or Exit the program. The underlying icons provideshortcuts to certain of these and other tasks as described below. If theuser chooses FILE>CREATE to create a new floor plan, the user may thenclick on>EXPRESS to initiate a new floor plan expediently. The user isthen prompted to enter the following input:

a. Floor plan Name (up to 8 character alpha/numeric).

b. Value of the Horizontal Dimension of the Total Horizontal Plan Width.

c. Value of the Vertical Dimension of the Total Vertical Plan Height

d. “Material Code” Input for Panel Lumber for Exterior Wall Thickness.The program assigns material codes to designate component materialproperties, and the user must select or define the material propertiesfor each code (as will be described). Once the forgoing data is enteredand a name chosen by the user, e.g., “bldg.”, a file by that name iscreated and is assigned a *.flp extension to designate that it is afloor plan.

If, on the other hand, the user chooses to Open an existing floor plan,the File Retrieval window of FIG. 2 appears. This window is segregatedinto four separate sub-windows including Directory, Floor plan,Associated Files and Floor plan Preview sub-windows. The Directorysub-window displays the computer folders and sub-folders in aconventional manner and allows the user to navigate the attached storagemedia to find the location of a pre-defined floor plan. The Floor plansub-window displays all floor plans with the *.flp extension in adesignated folder. The Associated Files sub-window shows all objectfiles which have been associated with a selected floor plan. Finally,the Floor plan Preview sub-window gives a graphical preview of aselected floor plan. Once the user has located a desired floor plan toopen, he clicks on the “OK” button to open that floor plan.

Once a floor plan is created or opened, the program returns to thePrimary Editing window of FIG. 1, and the user may navigate this windowat will in order to generate a completed floor plan. The user mustcomplete a number of “tasks” for completion of the floor plan, and eachtask involves one or more user “steps”. Once the appropriate steps aretaken to complete the prerequisite tasks, the user proceeds to theremaining tasks and is able to complete a Build routine (to bedescribed) that assimilates all previously input data and builds theactual three-dimensional floor plan. If the user attempts to run theBuild routine prematurely before the prerequisite tasks are completed, aconcise introductory checklist of tasks is displayed to inform the userof the prerequisite unfinished tasks (which are necessary to define allwall panels associated with a floor plan, and all detailed componentsassociated with all wall panels in the floor plan).

FIG. 3 shows a visual display 1 for the checklist of tasks. Again, theprogram generally will not present this particular visual display window1 until the user runs the Build routine (described below). However, thechecklist serves as a good point of reference in describing the overallprogram flow, and the program is herein described with reference to thetasks as they appear in visual display 1.

The checklist includes seven major substantive tasks 2-8 which the usermust complete in order to generate a proper floor plan.

The first task for completion 2 is to input all discrete wall panelsincluded in the floor plan, and to justify their accurate lengths.

The second task for completion 3 is to edit the wall panelspecifications (set in step 2 above) in order to set stud spacing andother construction details.

The third task for completion 4 is to place any necessary openingswithin the wall panels (the panels having been defined in steps 2 and 3above).

The fourth task for completion 5 is to set any Bearing, Rake, Hidden orOption Walls (set in step 2 above) as will be further described.

The fifth task for completion 6 is to select the walls that are to besheathed.

The sixth task for completion 7 is to run a Build routine thatassimilates all previously input data and builds the actualthree-dimensional Floor Plan.

The seventh task for completion 8 is to Cut the Sheathing in order tocalculate sheathing square footage (based on the walls selected to besheathed in the fifth task 6).

Throughout all of the above-described tasks, the computer program of thepresent invention tracks the progress of the user. When the user runsthe Build routine 8 (sixth task for completion 7), successful completionof each task is designated with a check mark in the appropriate checkbox 2-8 in visual display window 1.

Following execution of all of the above-required tasks 2-8, the floorplan is complete and can be printed, analyzed or edited at will. Anumber of useful reports can be generated to assist in ordering orshipping lumber.

In further accord with the present invention, the floor plan may betranslated into a marking layout for quantifying the framinginformation. This information can be transferred automatically anddirectly onto framing components to guide cutting, notching and/orplacement of associated members. In addition, the information can beused directly to drive an automated cutting/notching machine in order tocut and notch the stud locations for the wall panels.

While tasks 2-8 must all be completed, it should be understood that theyneed not be completed in the sequence shown. The user is free tonavigate the program at will, so long as the prerequisite tasks for theBuild routine 8 are completed. It is also noteworthy that componentsmust be defined and stored in a library prior to placement in the floorplan. Some users may choose to define and/or refine all existingcomponents initially, while others may prefer to define componentspiecemeal prior to adding them to the floor plan. In practical terms, alibrary of pre-defined components will be supplied with the program.Hence, the addition/editing of components will be described throughoutas an optional step prior to adding the particular component type to thefloor plan.

Completion of each major task 2-8 shown in the visual display of FIG. 3requires that the user perform a series of incremental steps to ensurethat all floor plan information is properly entered for that task. Oncethe checklist of tasks is completed past the Select Walls for SheathingTask 6, the program will allow the user to proceed to the Build! Stage 7wherein the actual three-dimensional floor plan model is compiled. Shortof this point the user is forced to Cancel out of the introductorychecklist of tasks shown in the visual display 1 of FIG. 3. Uponpressing the “Cancel” button, the user is returned to the PrimaryEditing window of FIG. 1 and may navigate this window at will to furthercomplete any unfinished prerequisite tasks.

All steps necessary to complete the checklist of tasks will now bedescribed with reference to FIG. 4, which shows a detailed flow-chart ofthe user steps necessary for completion. Other Figures will bereferenced as necessary to describe the graphical interface tools bywhich the user navigates and completes the program steps.

Referring back to the Primary Editing Window of FIG. 1, this is agraphical user interface which allows for convenient click-and-dragdefinition of any and all components of the floor plan. The floor planor component file which is presently being edited is shown at the toptitle bar along with the file path. To the extent that it has beendefined, a graphical representation of the floor plan being edited isshown in a viewer window. The windows-based text menu at the top andcorresponding series of graphical icons provide the user with anavigable means for accomplishing the entire underlying sequence ofsteps necessary to complete the entire checklist of tasks 1. While itshould be understood that various labels may be assigned to the menuitems and that different graphical icons may be used, the illustratedicons allow the user to perform the following (respectively, from leftto right):

OPEN: opens a floor plan file.

SAVE: saves a floor plan file

PRINT: prints a floor plan file

ZOOM: enlarges floor plan being edited is shown in a viewer window.

PAN: allows the user to click at a point in the viewer window and viewerbecomes centered there

DIMENSION: the user may click on DIMENSION and point to two edgesbetween which a dimension is desired. The dimension is automaticallycalculated and displayed.

ID: the user can click on ID to check the various parts of the plan.Another click on a wall and an ID Box appears in the upper left cornerdisplaying the following information. Name: the item designation.Length: overall length from end to end in feet and inches. Width: thewall width in inches. Base: the bottom plate elevation of the item.Depth: the actual height of the item in inches. Top: the top plateelevation in inches. Record: the internal record number used foridentification in the program (as will be described).

MOVE: When the user click on the MOVE icon the user will be prompted toclick on an object and drag it to its new location.

DIMENSION: When the user click on the DIMENSION BUTTON the user will beasked to click on the first object from which to measure the dimension,and then to click on the next object to complete the dimension. Atemporary dimension line will appear between the selected objects andthe dimension will be calculated and shown.

TRIM OBJECT: this prompts the user to “Select The Object You Wish ToTrim.” The user points and clicks on the object and it highlights inyellow. Next, the user is prompted to “Select The Edge You Wish To TrimIt To”. When the user points and clicks on an edge the object that washighlighted in yellow will again change color (e.g., to maroon) and thechose edge will be highlighted in yellow. Both object and edge will turnto black in a few seconds and the object will have been trimmed to theedge. This allows the user to input objects and then join them later toinsure that edges are touching.

TRIM EDGE: this tool is primarily used for trimming angle walls to theirfinal location. Once the user has established two walls at an angle, hecan trim the angle wall to the receiving wall with TRIM EDGE.

COPY: When the user clicks on the COPY BUTTON the user will be promptedto click on the item the user wish to duplicate. He clicks on that itemand immediately the component is duplicated. Now the user can click onMove to move that object wherever the user wishes.

ELEVATION: this will prompt the user to “Point To Item To Set BaseElevation”. When they click on an item it will highlight yellow and aCurrent Elevation Box will appear showing the current base plateelevation. The user enters the new elevation, in inches, and clicks OK.The bottom plate will be adjusted to the new elevation. Now the user cango back to the Depth Button right above the Elevation Button and enterthe new depth of the panel. At this point the panel will be fullyadjusted to the users requirements.

DEPTH: this allows the user to change the height of a wall easily. Theyare prompted to “Point To Item To Set Depth” The user clicks on an itemand it will turn yellow. At the same time the Current Depth Box willappear. If the user find that the overall height in inches should bechanged, simply type in the new depth and click OK. If the depth iscorrect just click CANCEL and go to the next item.

DELETE: When the user click on the DELETE BUTTON the object highlightedin black is registered for deletion. An information box appears and theuser must confirm deletion of the selected component.

UNDELETE: undeletes a deleted component.

SAVE: When the user click on the SAVE BUTTON an information box willappear, and prompts the user to confirm whether to save his edits.

HIDE/EXPOSE: hides or exposes hidden components (to be described).

BUILD: initiates the Build! Routine as will be described.

BUILD ERRORS: displays Build Routine Errors (as will be described).

FIT: When the user click on the FIT BUTTON it will automaticallyreposition the wall panel in the center of the box, and will unzoom thepreview screen.

The detailed sequence of the program will now be described withreference to the above-described graphical icons and menu items. FIGS.4a-4 f show the incremental steps taken by a user in the course ofcompleting tasks 2-8 of FIG. 3 (with dotted lines indicating theassociation between user steps and tasks 2-8).

The first task for completion 2 is to define the outer walls in thefloor plan. If the user has opened an existing file, the existing wallswill be shown in the viewer window. If the user has created a new floorplan, the outer walls are automatically generated and shown inaccordance with the Value of the Horizontal Dimension of the TotalHorizontal Plan Width, the Value of the Vertical Dimension of the TotalVertical Plan Height, and the Material Code Input all as specifiedinitially by the user. Otherwise, the outer walls must be added, definedand/or edited as desired. To accomplish this, the user adds walls atstep 30 by selecting ADD from the Primary Editing Screen of FIG. 1, thenWALL. The user is given the option to add the wall BY SKETCH or BYWORKLINES. In either case, the user must also select or define thematerial codes for the wall to be added in step 40 (as will bedescribed).

To add BY SKETCHI, the Material Code Screen of FIG. 5 appears and theuser may verify or change the wall size and species. Most material typesand grades are pre-defined and stored in a material library. However,these can be edited and new types and grades can be defined via theMaterial Code Editor of FIG. 5. The user must set material properties atstep 40 for each wall such as grade and species of all parts, studspacing, stud plys, wall sheathing, bracing, etc. For each wallcomponent, records are defined for each wall property and the recordsare stored in an object layer “.wac” that is associated with theparticular component being edited. The material properties that can bedefined include “Thickness”, “Width”, “Grade”, and material “Species”.New material specifications can be defined by the user by depressing theADD button at right, and existing material specifications can be editedby depressing the EDIT button. Once the material code is set, the userclicks OK and the Primary Editing Screen of FIG. 1 will return with aDONE Box in the upper left hand comer. The user is now able to sketchwalls in by click and drag in the viewer window. Specifically, the userselects the start position of the wall by clicking at that position onthe viewer window. A color-coded (yellow) hash mark will appear, and theuser drags the hash mark and releases to select the end position of thewall. The sketched wall appears in color (cyan) to indicate it has beenadded. When the user finishes sketching he clicks Done (at this time andthroughout it is a good idea to save the work). The wall turns to blackand the routine will terminate. All intended walls may be added in thismanner.

Alternatively, the user may add walls BY WORKLINES (click on WALL in thePrimary Editing Screen of FIG. 1 and then>BY WORKLINES). Again, theMaterial Code Screen of FIG. 6 appears and the user is prompted toverify or change the wall size and species as per above. Uponcompletion, the user clicks OK and the Primary Editing Screen of FIG. 1returns with a DONE Box in the upper left hand corner. In addition, amatrix of evenly-spaced gridlines or “worklines” is superposed on theEditing Screen. The user is now able to input the specified walls bypointing and clicking on the worklines appearing on the screen. When theuser is finished adding walls he clicks Done and the routine terminates.All intended walls may be added in this manner.

Once all walls are in place the user may add dimension strings to thefloor plan (FIG. 4 step 50). Dimensions strings are shown in the viewerwindow as point-to-point lines and the actual length of each string isautomatically calculated and shown proximate the string. To accomplishthis the user goes to the DIMENSION MENU and is prompted with thefollowing options for adding dimension lines.

ADD STRING: This option will allow the user to add a dimension line bypointing and clicking on walls to establish the beginning and endingpoints of dimension lines. When a dimension line has been established itis shown in color (maroon). The actual dimension is shown midway alongthe dimension line.

MOVE: when a dimension line has been established it may be moved byclicking and dragging the line, then clicking on the destination.

ON CENTER: When the user clicks ON CENTER he is prompted to “Select TheObject You Wish To Apply An On Center Dimension”. The user then selectsa point on the preview window and a yellow circle will appear indicatingthe start point of a dimension string. The user is then prompted to“Select The Place Where You Want The Label Placed”. The user points to aposition and is prompted to enter up to a 10-character dimension label.This is done and the user clicks OK. The label will appears in color.

DELETE: may be used to delete a dimension string.

AUTO: This menu tool allows the user to quickly dimension a plan. Onceselected the user is prompted to then select between HORIZONTAL orVERTICAL options. Should the user choose HORIZONTAL, he may point to aspot on the preview window and horizontal dimension strings willautomatically be created between all vertical walls. Should the userchoose VERTICAL, he may point to a spot on the preview window andvertical dimension strings will automatically be created between allhorizontal walls. In this manner the entire floor plan can be speckedout with exact dimensions.

The worklines also serve as a tool for changing component dimensions.Once a permanent dimension line has been added by the above commands,the user may select FORCE and manually enter a specific dimension. Theuser then clicks on the dimension line to be forced. The Value Box ofFIG. 9 will appear and the user may enter a specific dimension and clickOK. All affected walls and dimensions will be highlighted, and the usermay then point and click to deselect any affected parts. Once the userhas selected the dimension lines and components to change he clicksDONE. The dimension lines change to the specified dimensions and thewalls automatically are moved to their new locations. The user continuesas per the above until all walls have been appropriately defined anddimensioned.

Referring back to the introductory checklist of tasks to be completed bythe user in FIG. 3, the second major substantive task 3 that the usermust complete in order to generate a proper floor plan is to edit thewalls defined in task 2 above in order to set stud spacing and otherstructural details. This is shown as step 60 in FIG. 4b. To accomplishthis the user selects EDIT from the menu and>WALL CONFIGURATION. Thiscauses the “Configuration” Box of FIG. 6 to appear, and the user seesthe floor plan on the right (in maroon) together with a SPECIFICATIONLIST pull down menu on the left. The user clicks on the arrow to pullthe SPECIFICATION LIST menu down, and then clicks on the feature theywish to edit. Exemplary specifications include Stud Spacing, SectionSpacing Strong back Spacing, Wall Base Elevation, Mid-Block 1 Elevation,Mid-Block 2 Elevation, Section Elevation, and Wall Height. All of thesespecifications are pre-defined and have an assigned lumber type. Theexisting specifications are shown directly below, and assigned lumbertype below the preview window. However, if the user wishes to change thelumber specification, they may enter new specifications and/or click onthe CHANGE LUMBER button and choose a new configuration. Once thedesired specifications are set, the user goes to the UPDATE SELECTIONBox and chooses SOME or ALL. If they choose SOME, they must point andclick at the walls they want changed in the preview window. If they wantall the walls changed, they click ALL. The selected walls will changecolor (e.g., from maroon to yellow) indicating clearly what is beingchanged. To verify a change, the user can go back to the SPECIFICATIONLIST, click on the item, and see the new specifications in the EXISTINGCONFIGURATION List below. If there was more than one change, the itemschanged are shown in different colors to clearly distinguish. TheEXISTING CONFIGURATION list may vary depending on the item selected inthe SPECIFICATION LIST. For example, when making changes tospecifications which require a height designation, the user is presentedwith a new field called ENTER NEW VALUE. They must then type the newheight requirement and choose ALL or SOME. Again, the change will bemade and verified by going back to the SPECIFICATION LIST and clickingon that item. All stud spacing and other structural details may be setin this manner.

Referring back to the introductory checklist of tasks to be completed bythe user in FIG. 3, the third major substantive task 4 that the usermust complete in order to generate a proper floor plan is to place anynecessary openings within the floor plan. The openings mark thelocations in the floor plan for windows, doors and other components.Each opening can be selected from an existing library, or imported froma foreign library. Of course, a predefined library of openings mustexist prior to adding them to a floor plan, and a library will besupplied with the program. Nevertheless, the user may also define anopening by clicking EDIT and then>COMPONENT. This brings up theComponent Editor window of FIG. 7 and described below. The ComponentEditor window of FIG. 7 can be called upon to edit an existing libraryopening or it can be used to define a new opening. Either way, thesubject opening is depicted in a preview window at right. The framingcomponents used in the subject opening are denoted to the left by aseries of check boxes. Where applicable, data entry boxes are providedto the immediate right to designate the “Plys” of lumber used for theopening, the lumber material, and the length of the component,respectively. All of these component parameters can be input and/orchanged at will by the user. An Opening Specification area indicates thename of the wall panel shown in the preview window, as well as thelibrary (e.g., folder or sub-directory) in which it is stored, and allof the general dimensions for the subject opening. The opening materialmay be edited by the “Change Lumber” button shown at right, the selectedmaterial being shown directly beneath.

Once the user has defined his library of openings, he can begin to enterthe openings into the floor plan. This task 4 is represented as threesuccessive steps 70, 80 and 90 in the flow diagram of FIG. 4c. In thefirst step 70, the user specifies the rough openings that mark thelocations in the floor plan for windows and doors. In the second step80, the user specifies the rough opening locations in the floor plan fortubs, toilets, vent pipes, etc. In the third step 90, the user specificsthe rough opening locations in the floor plan for recessed medicinecabinets, electrical panels, and the like.

All information entered in step 70 to demarcate rough openings forwindows and doors is posted to the database in a layer of separate fileswith the *.opn extension.

All information entered in step 80 to demarcate rough opening locationsin the floor plan for tubs, toilets, vent pipes, etc. is posted to thedatabase in a layer of separate files with the *.hol extension.

All information entered in step 90 to demarcate rough opening locationsin the floor plan for recessed medicine cabinets, electrical panels, andthe like is posted to the database in a layer of separate files with the*.opn extension.

To add any of the above-described openings from the Primary EditingScreen of FIG. 1 to the open floor plan, the user selects from the menuADD and then 22 OPENING. The user is then given options on how to addthe opening, including QUICK, DIMENSION TO CENTER, DIMENSION TO EDGE, orBETWEEN WALLS.

When the user clicks on QUICK the Add Opening Box of FIG. 8 appears andeach pre-defined opening is designated by a label such as “BD”, as shownin the pulldown menu (top left). Each labeled opening is predefined bywidth, height, and top dimensions as shown at top right. A lower previewwindow is provided to show the structural appearance of the selectedrough opening. The user simply clicks on the opening they wish to placeinto the floor plan. This causes the OK button to highlight, and pictureof the component appears in the preview window along with all of thecomponent information shown to the right. If this is the correct theuser clicks OK.

When the user has clicked OK they are returned to the Primary EditingScreen of FIG. and may point to where they want the component. ThisQUICK selection is primarily for a cursory plan and is not intended forfinal plans.

When the user clicks on DIMENSION TO CENTER the Add Opening Box of FIG.8 appears and selection proceeds as above. However, when they arereturned to the Primary Editing Screen of FIG. 1 they are prompted to“Select Wall Receiving Component”. The user points to the wall on thefloor plan where they want the component located. Next, the user isprompted to “Select a Workline Or Reference Point To Start”. They clickon the wall or workline from which the centerline dimension will bestrung. The Value Box of FIG. 9 appears and the user enters the distanceto the center of the opening and clicks OK. The opening is automaticallylocated in the wall and all corresponding dimensions are automaticallycalculated.

When the user clicks on DIMENSION TO EDGE the Add Opening Box of FIG. 8appears and selection proceeds as above. Again, when they are returnedto the Primary Editing Screen of FIG. 1 they are prompted to “SelectWall Receiving Component”. The user points to the wall on the floor planwhere they want the component located. Next, the user is prompted to“Select a Workline Or Reference Point To Start” from which the edgedimension will be strung. The Value Box of FIG. 9 appears and the userenters the distance to the edge of the opening and clicks OK. Theopening is automatically located in the wall and all correspondingdimensions are automatically calculated.

When the user clicks on BETWEEN WALLS the Add Opening Box of FIG. 8appears and selection proceeds as above. However, after the user“Selects Wall Receiving Component” by point and clicking on the wallwhere the opening is to be located, they are prompted to “Select FirstWall To Place Component Between”. The user point and clicks on the firstwall, and a colored hash mark will appear. Then the user is prompted to“Select Second Wall To Place Component Between”. They point and click onthe second wall and the opening will be automatically locatedimmediately in the wall between the two walls which were selected.

The selection process continues until all desired openings have beenadded into the Primary Editing Screen of FIG. 1 and appear on the openfloor plan.

As adjoining walls are entered the user must also provide designinformation for wall intersections (FIG. 4c, step 100). Again, apredefined library of intersection types (or “cases”) must exist priorto adding them to the floor plan, and a library will be supplied withthe program. Nevertheless, the user may define their own wallintersections or edit library ones by clicking SETUP anthen>INTERSECTION. This calls up the Consumed Space Criteria setup ofFIG. 10, which is the user interface by which wall intersection criteriaare set. There may be different types of pre-defined intersections, andthe preview window shows Intersection Criteria Case #1. All otherpre-defined cases may be previewed by scrolling the scroll barunderneath. The intersection of two subject walls are shown in a previewwindow to the left with significant dimensional parameters labeledthereon. The labels for Case #1 include “minimum right nailing surfaceA”, maximum/minimum width B, filler C, left component D, and rightcomponent E. All significant dimensional criteria are shown in thecombination of pull-down menus and check and entry boxes at right,including minimum right nailing surface A, maximum and minimum width B,filler C type, horizontal orientation of the filler C, left componenttype, horizontal orientation of the left component type, right componenttype, and horizontal orientation of the left component type. Should theuser decide to edit any of these parameters he may click on EDITPREFERENCES and then enter the parameter he wishes to change. After theuser has made the appropriate changes he clicks SAVE INFO and EXIT.Specifically, Alternately, the user can click and drag a selectedcriteria of the intersection of the two subject walls to the desiredposition in the graphical viewer window and the dimensions as shown inthe check and entry boxes at right will change accordingly. Buttons areprovided to allow the user to edit the wall intersection criteria, saveedited criteria, clear the above-described fields, or exit from thissection of the program.

FIG. 11 illustrates an exemplary user interface for importingpre-defined wall intersection criteria or any other framing componentsor parameters from an existing library. All program files are stored ina namesake directory, and an entire layer of files corresponding tointersection criteria are stored in a subdirectory or folder called ISI(preferably, the collection of files for each type of framing componentor parameter is stored in a separate subdirectory or folder). Thecollection of files specifying intersection criteria are displayed tothe right. At bottom left a check box filter may be checked to limit thedisplay to a particular type of component (Doors/openings, Tees/cornerlibraries, or Intersection criteria). The user may select one or more ofthe file types listed and may import them into an existing floor plansimply by clicking import button.

The next step in completing the third task 4 is to cut the walls intopanels. There are a number of ways to accomplish this, all areaccomplished via the Primary Editing Screen of FIG. 1, and all areaccessible therein from the EDIT Menu by clicking on>CUT WALL.

The first menu option is CUT TO LINE. When this is selected the user isinstructed to “Place Cursor On Wall To Cut”, and then “Point To CutLine”. The wall will be cut and the user may proceed to the next wall tobe cut.

The second menu option is CUT TO DIMENSION. When this is selected theuser is instructed to “Place Cursor On Wall To Cut”. Once done, theValue Box of FIG. 9 will appear and the user may input the length of thewall to be cut. He clicks OK and the wall will be cut to the dimensionchosen.

The third menu option is QUICK CUT. The QUICK CUT option allows the userto randomly cut walls where needed. When this is selected the user needonly click in the viewer window at a point on the wall to be cut, andthe wall will be cut there.

Referring back to the introductory checklist of tasks to be completed bythe user in FIG. 3, the fourth major substantive task 5 that the usermust complete in order to generate a proper floor plan is to set anyBearing, Rake, Hidden or Option WaUs.

Load bearing walls are set at step 120 via the Primary Editing Screen ofFIG. 1 by selecting EDIT then>SET BEARING WALLS. The user may then pointand click on the walls that need to be coded as load bearing walls inthe plan. These walls change color in the preview window, e.g., tumingfrom black to cyan on the screen indicating that they are now classifiedas bearing walls. Once designated as such, the program knows that theselected walls are load bearing when adding trusses to the floor plan.

Rake walls are set at step 130, and these are walls having a top slope.These are necessary to accommodate sloped ceilings such as cathedralceilings. These rake walls are similarly designated from the PrimaryEditing Screen of FIG. 1 by selecting EDIT then>SET RAKE WALLS. The usermay then point and click on the walls that need to be coded as Rakewalls in the plan. Once designated as such, the program knows that theselected walls are rake walls and will automatically fit the top slopeto the adjoining sloped ceiling.

Hidden walls are set at step 140 and are those that should be ignoredwhen compiling the final floor plan so as not to affect adjoining walls.These hidden walls are similarly designated from the Primary EditingScreen of FIG. 1 by selecting EDIT then>SET HIDDEN WALLS. The user maythen point and click on the walls that 15 need to be coded as hiddenwalls in the plan, and they are shown in dotted lines. Once designatedas such, the program knows that the selected walls are hidden walls andwill ignore them so as not to impact the floor plan.

Option walls are set at step 150 and are those necessary to accommodateoptional components such as bay windows. Once designated as such, optionwalls can be turned on or off for purposes of compiling the final floorplan. These option walls are similarly designated from the PrimaryEditing Screen of FIG. 1 by selecting EDIT then>SET OPTION WALLS. Theuser may then point and click on the walls that need to be coded asoption walls in the plan, and they are color coded. Once designated assuch, the program knows that the selected walls are option walls andwill selectively compile or ignore them in the compiled floor plan.

Referring back to the introductory checklist of tasks to be completed bythe user in FIG. 3, the fifth major substantive task 6 that the usermust complete in order to generate a proper floor plan is to set thewalls or sections thereof to be sheathed. This information is used todemarcate the “Wall sheathing zones”, and this zone information isposted to the database in a layer of separate files with the *.shtextension. To add wall sheathing (FIG. 4d, step 190) from the PrimaryEditing Screen of FIG. 1, the user selects from the menu ADD andthen>ADD WALL SHEATHING. Again, the Material Code Screen of FIG. 5appears and the user is prompted to verify or change the wall sheathingspecifications. The user chooses from the Material Code Screen thesheathing they wish to use. The user may select SOME>OK, in which casethey are returned to the Primary Editing Screen of FIG. 1 and may pointand click on walls that sheathing is to be placed or changed. The usermay select ALL>OK, in which case they are returned to the PrimaryEditing Screen of FIG. 1 and all walls are sheathed. When the user isfinished sheathing walls he clicks DONE and the routine will terminate.All walls to be sheathed and their appropriate sheathing may bespecified in this manner. All walls to be sheathed are color coded andappear, e.g., as a green line. Sheathing may be deleted from the floorplan via the menu by selecting DELETE, and then SOME (allowing the userto point and click at the sections they wish to delete), or ALL(choosing this option will remove all sheathing). Alternatively, theuser may select EXCHANGE if they wish to exchange sheathing.

Next, if desired, at step 170 of task 5 beams and girders may be placedon the plan to develop concentrated loads. FIG. 12 shows the beamconfiguration window by which beams are added to the floor plan. TheBeam Configuration area allows user selection of basic beam attributessuch as “Flush” or “Drop” type, “Plys” and “Material Type”.Alternatively, a user-defined beam configuration is possible toaccommodate non-conventional beams. Selection of the user-defined beamconfiguration check-box enables entry of data into user-defined beamconfiguration area. Beam Post Specification Area allows entry of postscorresponding to each beam. A beam loading specification area isprovided to allow user-input of load constraints, and lumber selectioncan be changed at the Current Lumber window. The above beamconfiguration information is stored in a layer of separate files withthe *.bem extension.

Upon completion of the above-described steps the program will haveassimilated much of the component information for the floor planenvisioned by the user. The computer program tracks the progress of theuser and will indicate successful completion of major tasks 2-8 with acheck mark in the appropriate check box in FIG. 3.

All of the above-described component data selected or entered by theuser including location, length, width, and depth of walls, intersectioncriteria, rough openings and all other defined framing component pointsand attributes associated with the open floor plan are written to acomputer database file. All such points and attributes are stored in astandardized file structure called “Boxpoints”. The Boxpoints structureincludes the following defined variables.

Bottom Left X (x dimension for bottom left coordinate)

Bottom Left Y (y dimension for bottom left coordinate)

Top Left X (x dimension for top left coordinate)

Top Left Y (y dimension for top left coordinate)

Top Right X (x dimension for top right coordinate)

Top Right Y (y dimension for top right coordinate)

Bottom Right X (x dimension for bottom right coordinate)

Bottom Right Y (y dimension for bottom right coordinate)

Base Elevation (y offset from dimension for bottom left coordinate)

Depth (depth of framing component)

Pointer Variable (pointer to associated records)

Object Name (name of framing component)

Lumber Code (code indicative of type of lumber)

End Type

This structure can be used to store many types of objects in 3d bysaving the four side surfaces of the object as well as the top andbottom surfaces.

Component categories or “layers” are created by using a file or planname plus a dedicated object or layer name extension. For example, thewall panels for floor plan “Test” would be stored in “Test.flp”.Similarly, the openings for floor plan “Test” would be stored in“Test.opn”. All known object layers which use this structure and theirassociated file extensions are as follows;

Walls—.flp

Opening locations (windows, doors, medicine cabinets, recess panelsetc)—.opn

Floor System Section Boundaries—.jst

Beams—.bem

Holes (tubs, toilets, vents, piping, etc)—.hol

Knee Walls—.ane

Joists—.joc

Ducts—.auc

Wall parts (studs, openings, intersections)—.wac

Roof System Section Boundaries—.ros

Wall sheathing zones—.sht

Roof Trusses and rafters—.roc

Sheathing pieces—.shp

In addition to dimensional information, objects can have associatedattributes such as material type, etc. Further layers of attributeinformation are defined and associated with the layers of objects. Theattribute information is stored in two separate files. This separationof attributes from objects increases the video “redraw speed” of theobject itself when the attribute information is not needed. Knownattribute layers are as follows.

Wall attribute layers include the following:

Bottoms Top, and Double plate material types

Stud material type, spacing, plys, offset

Mid span blocking type, elevation, number of rows

Rake or sloping top or bottom surface of wall info

Associated ceiling planes

Joist attribute layers include the following:

Section elevation

Spacing

Direction

Depth

Loading Info

Joist Type (lumber, engineered, open web)

Plys

End conditions (top or bottom bearing, hanger info)

Beam attribute layer

Depth

Loading info

Beam type (lumber, engineered)

Plys

End conditions (top or bottom bearing, hanger info)

End bearing post configuration

The program uses this attribute information to create the individual“child parts” within the object layers as well as the parts physicalx,y,z world coordinates. For example, if Wall1 .flp is a record in theobject layer “.flp”, it will store the wall object Wall1 in 3d by savingthe four side surfaces of the wall as well as the top and bottomsurfaces. The associated record Wall1.waa in attribute layer “.waa”stores the information regarding where and how the studs and plates etcshould be created for “Wall1”. All records that store the physical size,location, and material type of the parts that belong to “Wall1” arestored in the associated object layer “.wac”. Each child record in“.wac” has its Pointer Variable set to refer back to its single parentrecord in layer “.flp”. If the user wanted to see a drawing of “Wall1”,the program would retrieve the height, width, and depth of “Wall1” fromthe “.flp” layer and would then search and include all child recordsfound in the “.wac” layer.

For ease of code purposes, information such as notes, dimensions, andlabels are also stored in their own layers using the Boxpointsstructure.

Once the first five major substantive tasks 2-6 are completed asdescribed previously, the database carries all information necessary togenerate a proper floor plan. All is ready for the sixth task forcompletion 7, which is to run the Build! routine in order to assimilateall previously input data and to build the actual three-dimensionalFloor plan. To accomplish this the user navigates the Menu as folows:GROUP>PANELS>BUILD ALL in order to run the Build Routine. Theintroductory checklist of tasks arises as shown in the visual display 1of FIG. 3. Completed tasks are checked, and uncompleted tasks are not.The program will allow the user to proceed to the Build! Stage 7 onlyupon completion of prerequisite tasks 2-6. Short of this point the useris forced to cancel out of the visual display 1. Upon pressing the“Cancel” button, the user is returned to the Primary Editing window ofFIG. 1 and may navigate this window at will to further complete anyunfinished prerequisite tasks. Once the user is cleared to proceed tothe Build! Stage 7, he hits the Build! Stage Button 7. The Build Routinethen initiates compilation of the computer database, checks for logicalerrors, and automatically adds studs and any other necessary componentsinto the floor plan. The Build Routine 7 generates the completed floorplan including all location marks, symbols, material, grades andplacement information of all intersecting entities are stored in acomputer file for said wall.

As shown in FIG. 4e, the Build Routine 7 comprises a series of ninesteps 180-260 which parse through the flp layer to “build” each wall.The Build Routine 7 uses a “consumed space” theory by placing the mostimportant to the least important objects inside the wall boundary. TheBuild Routine 7 builds each wall in order of the following prioritizedsteps.

180: Place bottom plate

190: Place top plate

200: Place double plate

210: Place window and door openings

220: Place beam bearing studs

230: Place intersection components

240: Place wall studs according to spacing if space is not alreadyoccupied by one of above

250: Place mid span blocks

260: Place sheathing cuts

This Build! routine creates all the physical parts required to constructthe individual walls. This “part” information is posted to the databasefor sorting and batching. If logical errors are found in the database,the user can manually correct the errors.

At step 270, the user is provided with a number of graphical tools toallow him to go back and refine his floor plan and/or correct logicalerrors. For example, from the Primary Editing Screen of FIG. 1, the usercan select (highlight) a wall panel and then navigate the Menu, pressingVIEW and then>WALL PANEL. The user is then confronted with a number ofoptions. Should the user select the>VIEW ONE option, then the Wall PanelSide View Box of FIG. 13 will appear. The Wall Panel Side View Box ofFIG. 13 initially shows a large blank preview screen on the left, asmall Panel Info description box in the upper right-hand corner, a smallfloor plan preview box in the middle right side (with the users openfloor plan showing) and a CLOSE button in the lower right-hand corner.The user simply clicks on a wall panel shown in the floor plan box. Theselected panel appears in detail in the larger preview window at left.At the same time, EDIT and PRINT buttons appear beneath the floor planpreview box. A number of HIDE buttons also appear and these allow theuser to filter out selected components from view. The Panel Infodescription box in the upper right-hand corner now shows all theinformation about the selected panel, and all individual componentspecifications appear in spreadsheet format beneath the Preview window.This preview feature serves as a simple cross-check, e.g., if the userforgot to cut the sheathing after the Build! routine, he can click onthe CLOSE button and go over and cut the sheathing. The user can alsoclick PRINT to print the selected Panel. If the user would like to editthe panel he may click EDIT to bring up the Panel Editing Window shownin FIG. 14. The Panel Editing Window of FIG. 14 includes a Panel Previewwindow which shows the selected panel. When the user clicks on an objectin the Panel Preview window the object will change color (e.g., turn toblack), thereby indicating the selection. A plurality of editing toolsappear as icons beneath the Preview Window, and these accomplish thefollowing functions (respectively, from left to right).

MOVE: When the user click on the MOVE icon the user will be prompted toclick on an object and drag it to its new location.

DIMENSION: When the user click on the DIMENSION BUTTON the user will beasked to click on the first object from which to measure the dimension,and then to click on the next object to to complete the dimension. Atemporary dimension line will appear between the selected objects andthe dimension will be calculated and shown.

ZOOM: When the user click on ZOOM BUTTON, they are prompted to selectthe center of where the user would like to zoom. This can be repeateduntil the user is content with the preview size.

LENGTH: When the user click on the LENGTH BUTTON the user will be askedto click on the object the user wishes to adjust. Once done, a boxappears showing the user the actual length and prompting for a newlength. The user enters the new length and clicks OK, thereby making theadjustment.

ADD COMPONENT: When the user clicks on the ADD COMPONENT BUTTON a pulldown menu of components appears. The user selects what the user wishesto add. Next the user is prompted to “accept” or “cancel” the selection.When the user “accepts” the Material Code Screen of FIG. 6 appears andthe user is prompted to verify or change the material codes. After doingso the user clicks OK, and the user is prompted to enter a dimension.Once done, the user is prompted to select the Move Button and may thendrag the object wherever the user wishes on the Preview Screen. The usermay fine tune the “x” and “y” locations manually by typing locationsinto the small X POS and Y POS boxes on the lower right side of thewindow.

FLIP: When the user click on the FLIP BUTTON it will automaticallyrotate the last object the user have clicked on.

JUSTIFY: When click on the JUSTIFY BUTTON it will automatically locateand right, left or center justify the last object the user selected.

COPY: When the user clicks on the COPY BUTTON the user will be promptedto click on the item the user wish to duplicate. He clicks on that itemand immediately the component is duplicated. Now the user can click onMove to move that object wherever the user wishes.

CHANGE GRADE/SPECIES: When the user click on CHANGE

GRADE/SPECIES BUTTON the user will be asked to click on the object whichthe user wish to have the wood grade or species changed. The MaterialCode Screen of FIG. 5 appears and the user may select the thickness,width, grade, and species for the object.

HIDE/UNHIDE: When the user click on the HIDE/UNHIDE BUTTON the user willbe asked to click on the object the user wish to hide. After the userclicks on that object an information box will appear asking the user“does the user wish to hide/unhide this item?” The user may click “Yes”,“No” or “Cancel”. When an object is hidden it is shown as a dottedoutline rather than a solid outline. When the user Unhides an object itturns back to a solid outline rather than the dotted outline.

DELETE: When the user click on the DELETE BUTTON the object highlightedin black is registered for deletion. An information box appears and theuser must confirm deletion of the selected component.

SAVE: When the user click on the SAVE BUTTON an information box willappear, and prompts the user to confirm whether to save his edits.

EXIT: This exits or leaves the Wall Panel Editor and returns to the ViewOne Panel screen ofFIG. 14.

FIT: When the user click on the FIT BUTTON it will automaticallyreposition the wall panel in the center of the box, and will unzoom thepreview screen.

REFRESH: When the user click on the REFRESH BUTTON the screen will beautomatically refreshed. (Note: all reference dimensions set up by theuser are erased).

A define component button appears below and this allows the user todefine any component on the fly.

Once all of the logical build errors have been manually corrected, theuser is presented with the “Build vs. Edit Discrepencies” window of FIG.15. This shows a side-by-side comparison of the original componentversion and the corrected version. The edits are not immediately postedto the database, and the user may selectively keep or discard the editedversion by clicking the appropriate KEEP button.

The seventh task for completion 8 is to cut the sheathing and to run asheathing routine that calculates the sheathing square footage based onthe walls selected to be sheathed in the fifth task 6. Sheathing may becut (FIG. 4f step 280) by selecting ADD>SHEATHING>CUT from the Menu. Theuser is prompted to either cut out the openings or to sheet through theopenings. The minimum sheathing square footage is automaticallycalculated from an optimal combination of cut patterns in light ofstandard sheathing sizes.

At this point all information and components corresponding to one storyof a finished floor plan is in the database and ready to be compiled.However, the intended structure may have two or more stories, and a fewfinal steps in the process may be necessary to account for multiplestory structures. These steps are shown at item 9 in FIG. 4f.

At step 290, the user can place heating and air-conditioning ducts onthe plan.

At step 300 the user can lay out the floor and/or roof system and insurethat any potential collisions are avoided.

At step 310 the user can associate the floor and/or roof layout with thewall stud layout to align the two. Proper alignment of the wall studswith the studs of the floor or roof system increases the structuralintegrity of the floor plan.

At step 320 the user can stack upper level floor plans “above” a lowerlevel plan to check vertical alignment of concentrated loads, stairwellalignment, etc. This may be accomplished by running a “Stacking routine”which automatically calculates loads and compares vertical alignments.

Throughout the above-described steps 290-320, the user is free to handedit any wall component for size or location. Again, this isaccomplished using the component editor shown in FIG. 7. The componenteditor can be called upon to edit an existing wall panel component bydouble-clicking on the given component shown in the Panel View Window(see FIG. 13).

Following execution of all of the above-required tasks 2-8, the Floorplan can be recompiled, generated, and printed or edited at will. FIG.16 is three-dimensional graphical illustration of a completed floor planwhich can be accessed by clicking VIEW>3D on the main menu.

In addition, a number of useful reports can be generated at step 340 toassist in ordering or shipping the necessary lumber, and to giveorganized material lists and cutting information for batches. Toaccomplish this, the user must select DATABASE>COMMIT PANELS from themain menu. This begins the process of exporting the three-dimensionalmodel data to a database format (Microsoft Access is currently beingused, though other commercial databases may be suitable). A CommitPanels Screen appears as in FIG. 17 and the user chooses a name andclicks OK to begin the Commit Process. A prompt appears letting the userknow that the information is being transferred into a database for usein creating reports. When the routine is finished the screen will returnto the Primary Editing Screen of FIG. 1. However, the database can beopened in Access, and FIGS. 18-23 illustrate exemplary reports that canbe gleaned from the database information and which simplifyadministration.

FIG. 18 is an opening cut list which lists all opening and opening typesin the floor plan and list of components by component type withspecifications necessary to build the openings.

FIG. 19 is an opening assembly list which lists all opening and openingtypes in the floor plan and a list of all components organized byopening.

FIG. 20 is a sheathing cut list which lists all sheathing sections to becut for all wall panels.

FIG. 21 is a lumber take-off list which totals the materials costs forall components.

FIG. 22 is a lumber pricing chart which lists the lumber SKU numbersused in calculating the materials costs in the report of FIG. 23.

FIG. 23 is a total pricing report which includes the saw costs andfabrication costs for all components.

Many other reports can be generated as desired.

Referring back to FIG. 4e, at step 330 the floor plan database may betranslated and used directly to drive an automated cutting and notchingmachine in order to cut and notch the studs for the wall panels. Anexemplary automated cutting and notching machine is shown and describedin U.S. patent application Ser. No. 08/587,960 filed Jan. 17, 1996 bythe same inventor herein.

Alternately, as shown at step 350 the Floor plan database can betranslated into a marking layout for marking studs to be cut by asawyer. A preview of an exemplary marking layout can be obtained byselecting PLATE CUTTING PREVIEW on the Primary Editing Screen of FIG. 1.The Plate Cutting Preview screen of FIG. 24 shows a top view of theselected Plate Component with marks for notches to be cut in accordancewith the assigned stud spacing. This marking layout can be automaticallyand directly transfered onto framing components for cutting, notchingand assembly thereof The marking layout is helpful in guiding manualcutting and notching, and the present invention includes the process anddevice for transferring the marking layout directly onto framingcomponents.

Referring now to FIGS. 25-42, the cutting and notching apparatus of thepresent invention will now be discussed. The arrangement or apparatusprovides for the controlled notching and cutting of components 1, suchas studs, wall plates, shelving, lattices and furniture. In thisrespect, the arrangement or apparatus cuts to length components 1 suchas the horizontal base plate 1 and parallel top plate 1 of a frame for awall, while simultaneously making transverse notches therein.

Alternatively (or in addition to the cutting), the arrangement orapparatus provides for the controlled marking of components 1 tofacilitate subsequent cutting and/or assembly.

The notching and marking apparatus 10 includes a support beam 11 forsupporting the framing components to be notched, cut and/or marked. Thesupport beam 11 includes a plurality of guide rails 12 that aresupported by an upright frame 13. A plurality of spaced-apart rollers 14(see FIG. 36) are disposed transversely between the guide rails 12. Thewood components 1 are supported on the rollers 14 and the components 1are easily moved from the entry to the exit of the apparatus. All of theguide rails 12 are substantially horizontal and substantially parallelto one another.

The frame 13 is a standard frame formed of welded steel beams andincludes support legs that rest upon a floor or foundation forsupporting the arrangement 10. Frame 13 may be arranged in variousconfigurations as will be described, but it is essential that frame 13support the guide rails 12 and various operative stations which performcutting, notching and/or marking operations on the wood components 1while in the guide rails 12.

A traveling component carriage 15 is carried by the support beam 11 nearone end thereof, and is capable of horizontal movement in eitherdirection along the length of support beam 11. The traveling componentcarriage 15 has an opening formed therethrough and the components 1 aredisposed longitudinally through the opening.

As best seen in FIG. 38, a gripping fixture 22 is mounted on componentcarriage 15 to grip the components 1 such that the components 1 moveconcurrently with the traveling component carriage 15. The grippingfixture 22 preferably is a pair of pneumatic cylinders mounted onopposing sides of the component carriage 15 and wielding inwardlypointed pistons toward the wood component 1, the pistons serving asgripping pins which secure the component 1 to the traveling componentcarriage 15. In this manner, the pins may be moved pneumatically towardone another to engage the components 1 therebetween and secure thecomponents 1 to the traveling component carriage 15. An optional secondgripping fixture 22 may be mounted on the opposite face of the travelingcomponent carriage 15 to better enable the components to be centered.Suitable pneumatic cylinders are manufactured by Numatics Co. as modelno. 0113BAAA2. However, it should be understood that other types ofactuators may be equally well-suited to serve on the component carriage15, and these may be pneumatically, hydraulically or electricallyactuated.

Referring back to FIG. 25, the traveling component carriage 15 advancesthe gripped base plate 1 and top plate 1 through a powered notchingstation 20 in a step-wise or continuous manner.

As seen In FIG. 28, movement of the traveling component carriage 15 isprovided by a belt 16 connected thereto, the belt 16 being driven by adrive wheel 17 connected to a stepper/drive motor 18. It is preferredthat the drive wheel 17 have a plurality of teeth formed on the outercircumference thereof (a sprocket). A continuous toothed belt 19 engagesthe teeth on the drive wheel 17 and also engages a toothed axle on thestepper/drive motor 18, the axle having a smaller circumference than thedrive wheel 17. In this manner, a small rotation in the axle of thestepper/drive motor 18 is transformed into a larger rotation of thedrive wheel 17 and thus, increased control over movement of thetraveling component carriage 15 is obtained. The stepper/drive motor 18is reversible. In this fashion, the traveling component carriage 15 isselectively stepped/driven to advance in a first direction along supportbeam 11, or to retract, reciprocally, in a second opposite direction.The traveling component carriage 15 moves in the first direction along 5support beam 11, and pushes the components into operational contact withthe notching/cutting/marking station 20. Notching/cutting/markingstation 20 is carried by the support means 11 near an end opposite thatof traveling component carriage 15.

A notching station 20 is provided for selectively notching 10 theframing components that are brought into contact therewith. As can bebest seen in FIG. 26, one embodiment of the notching station 20 includesa notching carriage 21. The notching carriage 21 carries powerednotching means for making transverse notches in the wall plates of theframe, as will be discussed at length below.

Also included in the notching station 20 is a wedging means 42.

As seen in FIGS. 29-35, the notching station 20 further includes atleast one, and in the case of a double-sided notcher, two dado-cut saws(powered notching means) 24. The dado-cut saws 24 which preferably are a20 plurality of ganged saws, are carried by the notching carriage 21 forselective substantially horizontal movement thereof. Such movement isprovided by means for moving (advancing and retracting) the powerednotching means vertically into engagement with the gripped wall plates1.

In the embodiment of FIG. 26, each notching carriage 21 is pivotallymounted on the frame 13. Each notching carriage 21 has a dado-cut saw 24carried thereon such that 5 each saw blade is substantiallyperpendicular to the longitudinal axis of the respective components 1.As the notching carriage 21 is pivoted toward the wall plates 1 andmoved downwardly, the dado-cut saw 24 engages the respective wall plate1 and begins cutting the notch 23 at the upper edge of the wall 10plate. As the notching carriage 21 completes the vertical movement, thedado-cut saw 24 is pivoted through a small arc to move the dado-cut saw24 away from the wall plate and to provide a notch 23 of a constantdepth in the wall plate 1. The dado-cut saw 24 is moved vertically in afirst direction and then in an opposite 15 second direction to notchspaced-apart notches 23 in the wall plates. Vertical pivotal movement ofthe notching carriage 21 is preferably activated pneumatically,hydraulically or electrically. The controller means 26 activates eachdado-cut saw 24 independently and also controls the pivotal motion ofeach 20 notching carriage 21 independently by providing individualcommands to the carriages 21 and the saws 24. In this manner, theengagement of each dado-cut saw 24 can be controlled to determine thedepth of the notch 23 formed in each component 1. Although in mostinstances, the notches 23 in both components 1 are of identical depth,the apparatus has the capability to produce a notch having a desireddepth which may be different in each component 1. The notch 23 may be ofa different depth at a first 5 location compared to a second location onthe same component 1. It is preferred that each dado-cut saw 24 beshielded for safety purposes.

FIG. 39 illustrates another embodiment of the notching station 20 withdouble-sided notchers. In the embodiment of FIG. 39, each notchingcarriage 21 is slidably mounted for vertical movement within the frame13. The notching carriages 21 are pneumatically raised or lowered intoposition by air cylinders 27. Air cylinders 27 are upwardly mounted toframe 13 and connected to the respective notching carriages 21 byconnecting rods for controlling their vertical movement within theframe. Each notching carriage 21 has a dado-cut saw 24 carried thereonsuch that each saw blade is substantially perpendicular to thelongitudinal axis of the respective components 1. The dado-cut saws 24are belt driven by motors 29, and 3 h.p. conventional Dayton IndustrialCo. drive motors are suitable for this purpose. The dado-cut saws 24 arepivotally mounted within their respective notching carriages 21 forcontrolled engagement with the wood component 1, and the dado-cut saws24 may be pivotally pneumatically raised or lowered into position by aircylinders 31.

Alternately, (and as pictured in FIG. 25) the dado-cut saws 24 can bereplaced by at least one, and in the case of a double-sided notcher, tworouters 24′. The routers 24′ are carried by the notching carriage 21 forthe selective vertical movement. The notching carriage 21 may be easilyadapted to move the routers 24′ downwardly and upwardly into engagementwith the gripped wall plates 1.

As seen in FIGS. 29-31, and with both of the embodiments of FIGS. 26 or39, the dado-cut saws 24 move downwardly and begin cutting the notch 23at the upper edge of the wall 10 plate. As the notching carriages 21complete their movement, the dado-cut saw 24 is pivoted through a smallarc to move the dado-cut saw 24 away from the wall plate and to providea notch 23 of a constant depth in the wall plate 1. The dado-cut saw 24is moved vertically in a first direction and then in an opposite 15second direction to notch spaced-apart notches 23 in the wall plates.Suitable pneumatic cylinders 27, 29 are manufactured by Numatics Co.However, it should be understood that other types of actuators may beequally well-suited to drive the notching carriages 21 and pivot thedado-cut saws 24, and these may be pneumatically, hydraulically orelectrically actuated.

Preferably, notching station 20 is capable of double-sided notching orrouting, in 15 which case a dado-cut saw 24 or a router 24′ is locatedon each side of the gripped base plate 1 and top plate 1, so as tostraddle the plates. The dado-cut saws 24 are horizontally movable tointercept the framing components as the dado-cut saws 24 are moved,preferably conjointly, toward one another. The routers 24′ may be 20vertically moved for making the transverse notches in the framingcomponents, so that the notches 23 are parallel and aligned with eachother. If desired, the notches 20 can be controlled so as to notch oneof the framing components independently of the other component.

Preferably, the notches 23 are in the form of a dado having parallelsides. The notch 23 may be of any desired depth. A depth ofapproximately ⅛ inch has been found to be effective to secure 5 thevertical stud in the plates. The alignment provided by this arrangementassures that a vertical stud will fit properly between the base plateand the top plate.

As seen in FIGS. 36 and 37, a cutoff saw 25 is carried by the supportrails 11 such that the notching station 20 is positioned between thecutoff 10 saw 25 and the traveling component carriage 15. The cutoff saw25 is provided for selectively cutting the framing components to adesired length subsequent to the notching operation. During furtheradvancement of the traveling component carriage 15, the components arepushed past the notching station 20 and into operational contact withthe cutoff saw 25. Preferably, the cutoff saw is a rotary saw.

Referring back to FIG. 25, the computer system 26 runs the software ofthe present invention as described above and directly controls operationand movement of the traveling means 15, the notching station 20 and thecutoff saw 25. In this manner, 20 controlled notching and cutting of theframing components, such as studs, wall plates, shelving, lattices andfurniture is provided. All controlled components may be connected bystandard electrical cables as known to those skilled in the art. Thecomputer 26 receives therein the user's input concerning the dimensionsand positioning of the wall panels, studs, etc. that are to form part ofthe framing. Computer 26 activates each dado-cut saw 24 independentlyand also controls the sliding and/or pivotal motion of each 20 notchingcarriage 21 independently by providing individual commands to thecarriages 21 and the saws 24. In this manner, the engagement of eachdado-cut saw 24 can be controlled to determine the depth of the notch 23formed in each component 1. Although in most instances, the notches 23in both components 1 are of identical depth, the apparatus has thecapability to produce a notch having a desired depth which may bedifferent in each component 1. The notch 23 may be of a different depthat a first 5 location compared to a second location on the samecomponent 1. It is preferred that each dado-cut saw 24 be shielded forsafety purposes.

FIG. 40 illustrates an exemplary marking device 40 incorporated in thecontext if the automated cutting/notching/marking machine of the presentinvention. The marking device 40 includes a printer such as an ink jetprinter which imparts the marking layout including all location marks,symbols, material, grades and placement information of all intersectingentities.

Lower print head 52 is mounted in a stationary position beneath supportrails 11, and an aperture beneath support rails 11 exposes the bottom ofcomponents 1 to the lower print head 52.

Upper print head 54 is mounted in vertically movable position directlyabove the support rails 11 (opposite lower print head 52). The upperprint head 54 is attached to a print carriage 55, which in turn isattached to a pair of air cylinders 57. Numatics Co. air cylinders arewell-suited for this purpose, and 250 psi models are acceptable. Aircylinders 57 are computer controlled to move upper print head 54 into orout of printing position with respect to component 1 while it is seatedin guide rails 11. Both air cylinders 57 may be mounted on anoverhanging stationary arm 58. A remote ink well 59 may also attached tocarriage 55, and is movable therewith and in fluid connection to supplyink to the upper print head 54. The ink jet print heads 52, 54 and aircylinders 57 are connected by conventional cables and are controlled bythe computer 26 which is running the application software describedabove. In all cases each stud, plate or wall panel may be encoded withan appropriate marking layout (as shown in FIG. 24) as it passes alongguide rails 11 to permit a person subsequently assembling the wallpanels to properly orient each wall panel and intersecting member withrespect to the overall floor plan as designed by the computer. Themarking layout as shown in FIG. 24 is transferred directly from thecomputer to marking device 40 and is imprinted onto framing componentsto guide subsequent manual cutting, notching and/or assembly.

The operation of the notching and marking apparatus 10 will now bediscussed with reference to the exemplary preparation of a wall plate.The operation is similar for other components for other applications andthe following is provided as a typical example and not as a limitation.

Following the detailed flow-chart of FIGS. 4a through 4 f, a user entersall necessary floorplan data into the computer, and the program designsdoor and window openings, tees, corners, electrical fixtures, etc. andenters the information into the aforesaid database. The length, widthand location of all walls is defined, as are wall heights, stud spacing,material, grades and sheathing locations. The computer automaticallyassigns truss direction, spacing, depth, loading, etc., andautomatically prepares a layout of walls and trusses to place allindividual components in each wall panel. The parts placement listingfor each panel is recorded in a file for subsequent determination ofcommands for the notching station 20. The computer 26 defines the orderin which the panels are to be notched and stacked. The computer 26 thencontrols all robotic movement to notch the components, cut thecomponents to the required length, mark subassembly locations, panelnumbers, truss 20 system component locations and wall intersectionlocations. In this manner, panels can be assembled either at the site ofthe apparatus 10 disclosed herein or at a remote site using the markingson the components. Component markings are provided for assembly of afull architectural plan or layout.

As shown in FIGS. 26 and 27, wall plates 1 (a horizontal bottom wallplate and a top wall plate that is to be parallel thereto) are placed onthe guide rails 12 and gripped within the traveling means 15 by grippingfixture 22.

An existing automatic feeder assembly may be used to load the wallplates 1 onto the machine table without any intervention by theoperator.

For the purpose of example only, the base plate 1 and the top plate 1(as well as the stud that is to be located therebetween) are wood 2×4's,and the notches are to be cut along the width of the respective 2×4's.

As shown in FIGS. 27 and 28, the computer 26 activates the stepper/drivemotor 18 to move the traveling component carriage 15 in the firstdirection until the traveling component carriage 15 contacts and engagesthe wall plates 1, and pushes (moves or advances) the plates 1 into thenotching station 20. Marking assembly 40 marks the base plate 1 and thetop plate 1 to encode each plate with specific information to permit aperson subsequently assembling the wall plates 1 and the studs, toproperly orient each wall plate with respect to the overall layoutdesigned by the computer. The marking assembly also transfers additionalinformation unrelated to the attachment of structural members butrelates to the placement with respect to other building materials andelements within the structure. At least one, and preferably two, wedgingmeans 42 are mounted on the frame 13. The wedging means 42 are activatedby the computer 26 and apply up to 500 psi pressure against the clampedwall plates 1 to reduce distortion in the plates before notching. In apreferred embodiment, the wedging means 42 has a substantiallyrectangular block disposed immediately adjacent to the teeth of thedado-cut saw 24. The block is attached to a piston which is received ina cylinder. The piston is moved into and out of the cylinder ascontrolled by the computer 26 to move the wedge into contact or out ofcontact with the wood components 15. Hydraulic, pneumatic or electricalpower may be used to power movement of the piston. The piston/cylindermay be perpendicular to the wood components or may be at an angle, aslong as movement of the block is produced to wedge the plate 1 firmly.The drive motor 17 is then stopped, and the double-sided notcher cyclesand both dado-cut saws 24 are advanced inwardly and downwardly intocontact with the wall plates 1, so that a first pair of the desirednotches are cut transversely in the wood plates 1 to a desired depth.The notches are parallel and aligned with each other. The dado-cut saws24 on both sides are retracted from contact with the wall plates 1. Aflexible vacuum tube may be connected to the notching station 20 tocollect shavings and dust generated during the notching procedure and tocarry the waste away from the work area. The stepper/drive motor 18 isthen reactivated and the traveling component carriage 15 incrementallyadvances the wall plates 1 by a predetermined length into a seconddesired position on the plates 1. A second double-sided notchingoperation then takes place in 10 which the dado-cut saws 24 are advancedinwardly and upwardly into engagement with the clamped plates 1, therebyforming a second pair of aligned notches 23 in the wall plates 1 spacedapart from the first pair of aligned notches 23. The stepper/drive motor18 may then be reactivated to move the 15 wall plates 1, as desired, andthe above-described process may be repeated as many times as desired forforming a plurality of pairs of spaced-apart transverse notches 23 alongthe length of the top and base plates 1. The dado-cut saws 24 movesequentially inwardly, downwardly, outwardly, inwardly, upwardly andoutwardly. The arrangement insures that the respective pairs of notches23 formed in the plates 1 will be properly aligned, and that a verticalstud will fit snugly between the two plates. When all desired notches 23have been cut, the stepper/drive motor 18 is reactivated, so as tofurther advance the plates 1 past the notching station 20 and intooperational contact with the cutoff saw 25.

Once in position, the computer 26 stops the operation of the travelingcomponent carriage 15, and the cut off saw 25 is activated toselectively cut the wall plates. The computer may control an automateddevice to remove the finished plates 1.

The computer 26 repeats the above-described process as many times asnecessary for notching and cutting the requisite number of wall plates.The spacing between the notches 23 and the length of each pair of wallplates 1 is determined by the computer program. A quality controlfeature of the system is a plurality of sensors 44 mounted on thetraveling component carriage 15, the dado-cut saws 24, the cut-off saw25, the marking means 40, the wedging means 42 and other criticalportions of the device. Each sensor provides feedback to the computer toensure each step is occurring in the proper sequence and that eachcomponent has been activated/deactivated as needed. It is also preferredthat means 48 be provided to remove or unload the notched components 1from the frame 11 after the cut-off saw 25 has cut the components 1 tothe desired length. The controller means 26 provides the commands to theunloader means 48 at the proper time to remove the notched components 1.In this manner, the entire sequence of operations from the loading ofthe components 1 onto the apparatus through the notching 5 and theremoval of the notched components 1, is controlled by the controllermeans 26 without participation or intervention of a human operator.

FIG. 41 shows a floor plan which is exemplary of the number andplacement of the notched studs which form the wall panels on one storyof a typical building. Once selectively notched and cut in the mannerdescribed above, the finished plates may be removed from the arrangement10 and placed on an assembly table. As illustrated in the assemblydiagram of FIG. 42, the studs and the components may be pieced togetherand fastened in place by, for example, nailing.

Operation of the present device to automatically and directly transfer amarking layout onto the framing components 1 will be described forsubsequent controlled cutting, notching, and placement.

Referring back to the block diagram FIG. 4e, at step 330, the Floor plandatabase is translated into a marking layout for marking studs to be cutby a sawyer and assembled. The marking layout can be previewed byselecting PLATE CUTTING PREVIEW on the Primary Editing Screen of FIG. 1.The Plate Cutting Preview screen of FIG. 24 shows a top view of theselected Plate Component with marks for notches to be cut in accordancewith the assigned stud spacing. To automatically and directly transferthe layout onto a framing component, a wood component 1 is fed into theguide rails 11, and automatic marking of component 1 is accomplished bymarking device 40 while component 1 is manipulated by the movingcomponent carriage 15. It is important to note that marking of plate 1may be performed independently of notching by employing those elementsof the device of FIG. 25 and the marking assembly of FIG. 40 asnecessary for marking, and notching station 20 may be omitted.

The present invention may also be adapted for portability so that it canbe moved to a job site and set up in the immediate vicinity of theconstruction to reduce transportation and material costs and to expediteconstruction. A portable arrangement has the same fundamental componentsas the arrangement described above and is operated in the same manner.Because the arrangement of the present invention guarantees that thenotches 23 formed in the parallel wall plates 1 are aligned, it assuresthe proper positioning of the studs in the frame and precludessubsequent misalignment of the studs due to warping or the like.

The arrangement 10 described above is also useful for producing soleplates members having shallow recesses or rabbets formed therein forlocating and receiving the lower ends of studding. With this device,there is no human intervention throughout the layout or dimensioningprocess, and assemblers are compelled to place the studding properly inthe notches. The aligned notches prevent the material from twistingafter manufacturing. Structural advantages are also provided by thenotches because they stabilize the walls and improve design values.However, if desired, the arrangement may be manually controlled toposition the plates, activate the notcher and cut the plates. Moreover,there are indirect advantages in constructing wall plates in accordancewith the present invention before shipment to the job site. This allowsdebugging of the plans on the computer. A larger volume of business canbe completed in a relatively small space. Freight dollars are saved bynot shipping defective components and by having no excess material inthe shipment since all components are precut to the required dimensions.Additional savings in shipping costs can be obtained by shipment of theunassembled wall plates which have been appropriately marked by themarking means 40. All of the intervening space in the framed unit issaved and shipping costs are significantly reduced. However, when thewall plates are received on site, the consumer must provide studs cut toproper lengths and must assemble the wall plates and studs as directedby the markings on the wall plates 1 and the layout.

Although the example described above is directed to wall plates andcomponents for architectural plans, the device is also useful with anymembers which require notching in a controlled and productionenvironment. Shelving, furniture and containers are other end productswhich are amenable to use of the present device.

It will be readily appreciated by those skilled in the art, that theapparatus of the present invention may find application for shaping andsurface treatment especially of any wood components. For this purpose,the notchers can be replaced by any appropriate wood-working means, forinstance, abrasive wheels, shaping means, etc.

The above-described example is also directed to automatic cutting andnotching of wall plates and components. Alternatively, the floor planmay be translated into a marking layout for quantifying the framinginformation, and this information can be transferred automatically anddirectly onto framing components to guide subsequent cutting, notchingand/or placement of associated members. An example of this marking willnow be described.

Obviously, many modifications may be made without departing from thespirit of the present invention. Accordingly, it will be appreciated bythose skilled in the art that within the scope of the appended claims,the invention may be practiced other than has been specificallydescribed herein.

Industrial Applicability

Framing is a common method for the construction of buildings having upto four stories. The placement of the components in the building isdetermined by a set of construction documents called blueprints. Theblueprints define each and every dimension and location for everycomponent in the building. However, mistakes can easily be madethroughout the process. First, mistakes can be made when formulating theblueprints. Second, mistakes can be made when reading and transferringmarker information from the blueprints to the wood components. Third,mistakes can be made by mis-cutting the components. Finally, mistakesmay be made at the assembly point by misunderstanding the markerinformation or missing the mark when nailing. There have been relativelyfew prior efforts to automate the framing process, and only a fewcomputer systems for generating 3D models of framed structures forconstruction purposes. Thus, there clearly remains a need for a systemwhich provides a parametric modeling program that allows a user toquickly and conveniently generate 3D models of framed structures, amarking layout for quantifying the framing information, and a processfor automatic computerized transfer of the marking layout onto framingcomponents for controlled cutting, notching and assembly thereof.

What is claimed is:
 1. An apparatus for notching wood components,comprising: an elongate supporting frame; an automatic notching stationcarried by the supporting frame, said notching station including anotching tool having at least one dado-cut saw for notching said woodcomponents, and a notching carriage pivotally and transverselyarticulated to said frame for moving said notching tool into cuttingcontact with said wood components; a traveling component moving carriagesupported by and selectively positionable lengthwise along saidsupporting frame for advancing wood components into a notching positionrelative to said notching station; a programmable controller connectedto said automatic notching station and component moving carriage forcoordinating and controlling operation thereof, said programmablecontroller sequentially advancing said wood components into notchingposition relative to said notching station, moving said notching toolinto cutting contact with said wood components, and automaticallynotching said wood components in accordance with predetermined designconsiderations.
 2. The apparatus for notching components according toclaim 1, further comprising a cut-off saw carried by the support meansand connected to said programmable controller for cutting the componentsto a required length.
 3. The apparatus of claim 1, wherein thecomponents include a pair of identical components brought into contacttherewith.
 4. The apparatus of claim 3, wherein the notching tool is adouble-sided notching assembly, and said component moving carriage movessaid pair of identical components into operational contact with thedouble-sided notching assembly for notching both componentssimultaneously.
 5. The apparatus of claim 1, wherein the notchingstation includes a pair of notching tools carried by a pair of notchingcarriages.
 6. The apparatus of claim 5, wherein the pair of notchingtools further comprises first and second dado-cut saws, respectivelysecured to the supporting frame by a first and a second notchingcarriage.
 7. The apparatus of claim 1, further including a markingassembly for marking each component with a marking layout to facilitateassembly of said components in a predetermined order.
 8. The apparatusof claim 1, wherein the programmable controller comprises a computer.